Tape Head for Sealing Cases

ABSTRACT

Structural and operational techniques for a tape head sealer are described herein. In one example, a tape head utilizes a first actuator to drive leading and trailing rollers and a second actuator to drive a tape-cutting knife. In some examples, the actuators may be air-powered cylinders. However, solenoids, hydraulics, motors and/or other devices may be used as actuators. In the example, a first air-powered cylinder may drive the leading and trailing rollers and a second air-powered cylinder may drive the tape-cutting knife. The leading and trailing rollers press tape against the case to thereby adhere the tape to the case to seal it. The second air-powered cylinder may extend a tape-cutting knife to cut the tape. After the tape has been cut, the knife may be retracted.

RELATED APPLICATIONS

This patent application claims priority to U.S. patent application Ser.No. 62/192,465, titled “Tape Head for Sealing Cases”, filed on 14 Jul.2015, commonly assigned herewith, and hereby incorporated by reference.

BACKGROUND

In a case erecting and sealing machine, a tape head applies tape to anerected case (e.g., cardboard box) to seal the top and/or bottom of thecase. In an example, cases begin in a folded-flat configuration, areerected, the bottom is sealed, the case is packed with product, the topflaps closed and then sealed with tape. The process may include aconveyor that moves the case through a plurality of stations whereincase erection, product packing and case sealing are performed.

Known tape heads tension a spring in response to contact of a leadingroller of the tape head with a leading side of an on-coming case that ispropelled by a conveyor. Initial contact between the leading roller andthe case presses tape against a leading side of the case. Continuedcontact between the leading roller and a trailing roller presses tapeagainst the closed flaps of the case, thereby closing the case. Thetension in the spring is used to move the trailing roller against andend of the tape to be secured to the trailing side of the case. Thus, apiece of tape joins the closed flaps of the case, and also extends ontothe sides of the case.

A problem with such tape heads is that contact with the leading roller,sufficient to tension the spring, may deform the case. Such deformationis particularly likely if the case is not fully packed with ridgedproduct. However, such tensioning is required by such systems to propelthe trailing roller against the trailing side of the case, to therebysecure the end of the tape, after it has wrapped over the trailing sideof the case.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is described with reference to the accompanyingfigures. In the figures, the left-most digit(s) of a reference numberidentifies the figure in which the reference number first appears. Thesame numbers are used throughout the drawings to reference like featuresand components. Moreover, the figures are intended to illustrate generalconcepts, and not to indicate required and/or necessary elements.

FIG. 1 is an isometric view of a tape head having the roll of taperemoved for clarity.

FIG. 2 is a side orthographic view of an example tape head in a statewherein a leading side of a case, moving right to left, has moved intocontact with a leading roller.

FIG. 3 is a side orthographic view of an example tape head in a statewherein the leading roller has pressed tape onto the leading side of thecase and is almost ready to transition from pressing against the leadingside of the case to pressing against the top of the case.

FIG. 4 is a side orthographic view of an example tape head in a statewherein the leading roller is beginning to press tape against theadjacent flaps of the top of the case. The trailing roller has beenraised to an elevation of the leading roller and will begin to presstape against the top flaps of the case when the case has advancedsufficiently.

FIG. 5 is a side orthographic view of an example tape head in a statewherein the trailing roller is pressing tape against the top of the caseand the case has moved beyond contact with the leading roller.

FIG. 6 is a side orthographic view of an example tape head in a statewherein the knife blade mount arm has pivoted to a location at which itwill cut the tape. The trailing roller has pressed the length of tapejoining the flaps on the top of the case and is about to press tapeagainst a trailing side of the case.

FIG. 7 is a side orthographic view of an example tape head in a statewherein the trailing roller is positioned to press tape against thetrailing side of the case, as the case continues to move to the left.

FIG. 8 is a side orthographic view of an example tape head in a statewherein the trailing roller presses an end of a piece of tape againstthe trailing side of the case.

FIG. 9 is a flow diagram showing an example of the operation of a tapehead for sealing cases.

DETAILED DESCRIPTION Overview

The disclosure describes techniques for tape head structure andoperation. In one context, a tape head is configured for use with caseerection machinery that opens, assembles, fills and seals cases (e.g.,cardboard boxes). Such cases may originally be configured in a stack offolded cases. At a first location along a conveyor, case erectionmachinery may grasp a case and open it from a folded-flat configurationinto a three dimensional form. At a second location along the conveyor,a tape head may seal the flaps that form the bottom of the case. Fartheralong the conveyor, the case erector may then fill the case with product(e.g., retail-packaged goods). At a still farther location, the tapehead may seal the flaps on the top of the case.

An example illustrating some of the tape head structure and operationaltechniques discussed herein—not to be considered a full or comprehensivediscussion—may assist the reader. In the example, a tape head utilizesone or more actuators to drive the leading and trailing rollers, one ormore tape guides, and a tape-cutting knife. In some examples, theactuators may be air-powered cylinders (i.e., air cylinders powered bycompressed air and/or partial vacuum). However, solenoids, hydraulics,motors and/or other devices may be used as actuators.

In the example, a first air-powered cylinder may drive leading andtrailing rollers and a second air-powered cylinder may drive atape-cutting knife. The leading and trailing rollers may be mechanicallylinked, so that the first air-powered cylinder drives both rollers asthe case approaches the rollers, contacts the rollers and then passesthe rollers. (Alternatively, the leading and trailing rollers may eachbe driven by a separate actuator.) The first air-powered cylinder movesthe rollers so that the leading roller presses tape to a leading(typically vertical) side of the advancing case. As the case advances onthe conveyor, the first air-powered cylinder moves the rollers so thatthe leading roller presses tape against adjacent closed flaps on the top(i.e., typically horizontal side) of the case. As the case advancesfarther, the trailing roller also contacts the tape and presses itagainst the closed flaps. And as the case advances still farther topositions beyond contact with the leading roller, the first air-poweredcylinder moves the rollers so that the trailing roller presses tapeagainst a trailing (typically vertical) side of the advancing case.

Also in the example, a second air-powered cylinder may extend atape-cutting knife to cut the tape. While the timing depends on thedimensions of the case being taped, the second air-powered cylinder mayadvance the knife after the case has advanced past the leading roller,but is still in contact with the trailing roller. After the tape hasbeen cut, the knife may be retracted.

Example System and Techniques

FIG. 1 shows an example tape head 100 usable with machinery, such ascase erection machinery, wherein tape is used to seal flaps of a case.In the example shown, a case may move in direction 102 with respect tothe tape head. A tape roll mandrel 104 is supported by a tape rollsupport arm 106. The mandrel 104 and support arm 106 support a roll ofadhesive tape that may be used to seal the flaps of a case.

A leading roller 108 makes initial contact with a case advancing indirection 102. In operation, the leading roller 108 presses a first endof a segment of tape against the leading side of a case as the caseadvances on a conveyor. The leading roller rolls up the side of the caseas it advances, pressing tape against the vertical leading side of thecase. The leading roller 108 then presses tape against the top of thecase, sealing together two adjacent edges of two adjacent flaps.

The trailing roller 110 initially makes contact with the case after theleading roller 108 has pressed tape against the top of the case. Thetrailing roller 110 presses the tape against the adjacent flaps on topside of the case, in a manner similar to actions already performed bythe leading roller 108. The trailing roller 110 then rolls down thetrailing (typically vertical) side of the case as it advances, pressingtape against the vertical trailing side of the case. Accordingly, theleading and trailing rollers press the tape against the flaps on the topof the case, while the leading roller 108 presses tape against theleading side of the case and the trailing roller 110 presses tapeagainst the trailing side of the case.

The leading roller 108 and trailing roller 110 may move in a relatedmanner as a result of interconnected roller support arms, brackets,linkages and/or other means. For example, first and second support arms,supporting the leading and trailing rollers, respectively, may be movedby an air-powered cylinder or other actuator in accordance with one ormore connecting linkages. Such interconnection(s) allow both rollers tobe driven by one roller-controlling air cylinder 112. Theroller-controlling air cylinder 112 may be configured so that airfittings at each end allow the piston to be pushed in both directions.Accordingly, the leading and trailing rollers may be lowered to aposition wherein they contact the sides of the advancing case, andraised to a position wherein they contact the top of the case.Accordingly, the roller-controlling air cylinder 112 and/or linkage movethe leading and trailing rollers 108, 110 about their respective pivots,in unison and/or simultaneously.

The roller-controlling air cylinder 112 may be supported at one end by arod end 114 or pivot. The cylinder 112 may be supported at the other endby a mounting bracket 116. Thus, the roller-controlling air cylinder 112may move somewhat, as the piston is pushed to different locations withinthe cylinder by application of compressed air to one or the other of thetwo ends, and as the rollers 108, 110 are moved into extended andretracted positions.

A pivoting support arm 118 for a tape-cutting knife is configured topivot between a retracted position wherein the tape is not cut, and anextended position wherein the tape is cut. The pivoting support arm 118is moved between the retracted and extended positions by aknife-controlling air cylinder 120. Air pressure alternately applied toopposite ends of the cylinder 120 allow the location of a knife to beprecisely controlled with respect to time and/or a location of one ormore cases on a conveyor line. In the example shown, one end of theknife-controlling air cylinder 120 may be attached to a fixed location126 and the other end (rod end 122) may be attached to the pivotingsupport arm 118 at pivot 124.

The roller-controlling air cylinder 112 and the knife-controlling aircylinder 120 are configured to allow compressed air to be introduced, inan alternating, sensor-controlled and/or program-controlled manner, toeach end of the respective air-powered cylinder. The compressed airmoves a piston (in a direction based on which end of the cylinder isreceiving compressed air) within each cylinder to a position to locatethe rollers or knife in an appropriate location based on time, alocation of a case, or other factor.

FIGS. 2 through 7 show an example tape head in a sequential series ofviews as a case moves from the right to the left. Accordingly, thestructure and operation of different components is shown.

FIG. 2 shows the example tape head 100 in a state of initial contact 200wherein a leading side 204 of a case 202, moving right to left, intocontact with a leading roller 108 and a tape guide 206. The leadingroller 108 is lowered to press tape against the leading side 204 of thecase 202. As the case 202 moves to the left, the tape guide 206positions tape (tape not shown for clarity) adjacent to, and the leadingroller 108 presses the tape against, the leading side 204 of the case202. In examples wherein the trailing roller 110 is linked to theleading roller 108 for movement in response to a single actuator, thetrailing roller is also lowered. The pivoting support arm 118 for theknife may be in an extended or lowered position at this stage; however,it will be retracted or raised before the case 202 arrives at itslocation, to thereby avoid contact with the case. A support arm 208supports the trailing roller 110 and is configured for rotation aboutpivot 210. A bracket 212, connected to the support arm 208, also rotatesat pivot 210. The bracket 212 is driven by the rod end 114 of theroller-controlling air cylinder 112, and drives a linking rod 214. Thelinking rod 214 is links to, and drives, a support arm 216 carrying theleading roller 108. The support arm 216 rotates about pivot 218, tothereby provide a range of movement to the leading roller that isconsistent with pressing tape against the leading side 204 and the topof the case 202.

FIG. 3 shows an example tape head 100 in a state 300 wherein the leadingroller 108 has pressed tape onto the leading side 204 of the case 202and is almost ready to wrap around the corner of the case to press tapeagainst the adjacent flaps of the top 302 of the case. The support arm216 of the leading roller 108 has rotated about a pivot 218 in responseto contact with the leading side 204 of case 202. Accordingly, theleading roller 108 has moved both to the left and upwardly in the viewshown (as compared to FIG. 2), to thereby maintain contact with tape tobe pressed against the leading side 204 of the case 202.

FIG. 4 shows an example tape head 100 in a state 400 wherein the leadingroller 108 has wrapped around the corner of the case 202 and isbeginning to press tape against the adjacent flaps of the top 302 of thecase. The trailing roller 110 has been raised to an elevation of theleading roller 108 and will begin to press tape against the top flaps ofthe case when the case 202 has advanced sufficiently. Theknife-controlling air cylinder 120 has moved the pivoting support armfor the knife 118 into a position above the case 202, to thereby allowthe case to pass under the knife.

FIG. 5 shows an example tape head 100 in a state 500 wherein the leadingroller 108 is no longer in contact with the case 202 and the trailingroller 110 currently pressing tape against the top 302 of the case 202.

FIG. 6 shows an example tape head 100 in a state 600 wherein the knifeblade mount arm 118 has pivoted in response to action byknife-controlling air cylinder 120 to a location at which it will cutthe tape. The trailing roller 110, attached to support arm 208 andmoving about pivot 210, has pressed the length of tape to join the flapson the top 302 of the case 202 and is about to go around the top casecorner and press tape against a trailing side 602 of the case 202.

FIG. 7 shows an example tape head 100 in a state 700 wherein thetrailing roller 110 is positioned to press tape against the trailingside 602 of the case 202. As the case continues to move to the left, thesupport arm 208 of the trailing roller 110 will rotate about pivot 210and keep the trailing roller in contact with the tape to be pressedagainst the trailing side 602 of case 202. The knife-controlling aircylinder 120 has positioned the pivoting support arm 118 of the knifeinto a position wherein the tape (not shown) was contacted by the knife,and has been cut. The tape guide 206 has rotated into a position thatwill assist in guiding an end of the tape not attached to the case 202into a position wherein the roller 108 presses the tape into contactwith a second case (not shown) that is moving into position on theconveyor belt (not shown).

FIG. 8 shows an example tape head 100 in a state 800 wherein thetrailing roller 110 is pressing an end of a piece of tape against thetrailing side 602 of the case 202. The leading roller 108 is in positionto press tape against a leading side of a case that has not yet arrived.The tape guide 206 is in position to guide tape to the leading side ofthe case that will soon arrive.

Example Methods

FIG. 9 is a flow chart showing an example method 900 to operate a casesealer. The methods and operation may be performed and/or directed byany desired integrated circuit, logic devices, programming, etc. Theexample methods of FIG. 9 may be implemented at least in part using thetechniques of FIGS. 1-8. However, the methods of FIG. 9 contain generalapplicability, and are not limited by other drawing figures and/or priordiscussion. The functional blocks of FIG. 9 may be implemented bysoftware and/or hardware structures or devices that are configured tooperate a case sealer and/or tape head device. In one example, one ormore functional blocks may be implemented by techniques and devicesincluding a microprocessor, a controller, a microcontroller, a ladderlogic device, or other general- or specific-purpose logic or controldevice, etc. Additionally or alternatively, one or more memory devices,computer-readable media, application specific integrated circuits(ASIC), software blocks, subroutines, programs, etc., may also beutilized. Computer-readable media, as the term is used herein, includes,at least, two types of computer-readable media, namely computer storagemedia and communications media. Computer storage media includes volatileand non-volatile, removable and non-removable media implemented in anymethod or technology for storage of information such as computerreadable instructions, data structures, program modules, or other data.Computer storage media includes, but is not limited to, RAM, ROM,EEPROM, flash memory or other memory technology, CD-ROM, digitalversatile disks (DVD) or other optical storage, magnetic cassettes,magnetic tape, magnetic disk storage or other magnetic storage devices,or any other non-transmission medium that can be used to storeinformation for access by a computing device. Computer storage media maybe non-transitory in nature. In contrast, communication media may embodycomputer readable instructions, data structures, program modules, orother data in a modulated data signal, such as a carrier wave, or othertransmission mechanism. As defined herein, computer storage media doesnot include communications media.

FIG. 9 is a flow diagram showing an example processes 900 which arerepresentative of techniques for use in case sealing. The processes may,but need not necessarily, be implemented in whole or in part by themicroprocessor 902 and/or the memory 904. Microprocessor 902 and/ormemory 904 may be part of a case erector machine and/or part of the tapehead of such a machine. The microprocessor 902 and the memory 904 andassociated programming may control actuators (e.g., compressedair-powered cylinders) that in turn move other mechanical parts. Actualcontrol may be based solenoid controlled valves, electrically controlledmotors, etc. Accordingly, programming may be stored in memory 904 andexecuted by the processor 902 to control and operate actuators, motors,valves, compressed air-driven cylinders, etc., to thereby operate thetape head 100 and/or associated machinery.

At operation 906, a leading roller is positioned to contact a leadingedge of an advancing case. In the example of FIG. 2, the leading roller108 is fully lowered, such as by operation of an air-powered cylinder(e.g., 112 of FIG. 1) or other actuator. The example shows that the casehas advanced (such as by movement on a conveyor, not shown) to a pointwherein the leading side 204 of the case 202 has just contacted theleading roller 108.

At operation 908, the leading roller presses a first end of a piece oftape against a leading side of the case. In the example of FIG. 3, theleading roller 108 moves upwardly as it presses the tape against theleading side 204 of the case 202.

At operation 910, the leading roller moves around the corner, from thevertical leading side to a horizontal top of the case, to press the tapeagainst adjacent flaps of the top of the case. In the example of FIG. 4,the leading roller 108 has been elevated to press the tape against theadjacent flaps on the top 302 of the case 202 to thereby seal thoseflaps together.

At operation 912, a trailing roller, in a manner similar to the leadingroller before it, presses the tape against the adjacent flaps on the topof the case as the advancing case moves below it. In the example of FIG.5, the case 202 has moved past the leading roller; however, the trailingroller 110 continues to press the tape against the adjacent flaps of thetop 302 of the case 202.

At operation 914, a knife, optionally carried by a pivoting support arm,is lowered into position to cut the tape. As seen in the example of FIG.6, the knife and arm 118 may be moved by operation of an air-poweredcylinder 120 or other actuator.

At operation 916, a tape guide is extended into a position that willguide an end of the tape created by the cut at operation 914 so that itcontact a case that is moving toward the tape head. As seen in theexample of FIG. 7, the tape guide 206 is lowered into position, whereinit will guide an end of the tape on the mandrel 104 into contact with aleading side of an advancing case.

At operation 918, a second end of a piece of tape (the second of thetape segment having the first end discussed at operation 908) is pressedagainst a trailing side of the case. In the example of FIG. 8, thetrailing roller 110 rotates about a pivot 210 to press the tape against,and adhere it to, the trailing side 602 of the case 202.

Conclusion

Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described. Rather,the specific features and acts are disclosed as exemplary forms ofimplementing the claims.

What is claimed is:
 1. A tape head, comprising: leading and trailingrollers; a roller-controlling actuator to move the leading and trailingrollers; a knife to cut tape; and a knife-controlling actuator to movethe knife; wherein the roller-controlling actuator and theknife-controlling actuator operate the leading and trailing rollers topress the tape against flaps of a case and to cut the tape,respectively.
 2. The tape head of claim 1, wherein at least one of theroller-controlling actuator and the knife-controlling actuator areair-powered cylinders.
 3. The tape head of claim 1, wherein theroller-controlling actuator is an air-powered cylinder powered bycompressed air and configured to allow the compressed air to beintroduced, in an alternating manner, to each end of the air-poweredcylinder.
 4. The tape head of claim 1, additionally comprising: alinkage between the leading and trailing rollers to cause the leadingand trailing rollers to move in simultaneously.
 5. The tape head ofclaim 1, wherein the leading roller is configured to press the tapeagainst a leading side and a top side of the case, and wherein thetrailing roller is configured to press the tape against the top side anda trailing side of the case.
 6. The tape head of claim 1, wherein theleading and trailing rollers are supported by first and second supportarms, respectively, and pivot about first and second pivots,respectively, and wherein the first and second support arms areconnected by a connecting linkage.
 7. The tape head of claim 1, whereinthe leading and trailing rollers are supported by first and secondsupport arms, respectively, and pivot about first and second pivots, topress tape against a leading side of the case, a top of the case, and atrailing side of the case.
 8. A method, comprising: under control of oneor more processors configured with executable instructions: positioninga leading roller to contact an advancing case by operation of anactuator; pressing a first end of a piece of tape against a leading sideof a case by operation of the leading roller; pressing the tape againstadjacent flaps of a top of the case by operation of the leading roller;pressing the tape against adjacent flaps of the top of the case byoperation of a trailing roller; and pressing a second end of the pieceof tape against a trailing side of the case by operation of the trailingroller.
 9. The method of claim 8, additionally comprising: lowering aknife into a position to cut the tape, wherein the knife is moved byoperation of an air cylinder.
 10. The method of claim 8, additionallycomprising: extending a tape guide to position tape for contact with asecond case.
 11. The method of claim 8, wherein operation of the leadingroller and operation of the trailing roller comprises moving in responseto first and second support arms, respectively, and pivoting about firstand second pivots, respectively, and wherein the moving and the pivotingis driven at least in part by a connecting linkage.
 12. The method ofclaim 8, wherein operation of the leading roller and operation of thetrailing roller comprises moving in response to first and second supportarms, respectively, and pivoting about first and second pivots,respectively, and wherein the moving and the pivoting positions theleading roller and the trailing roller at similar elevations as theymove.
 13. The method of claim 8, wherein the actuator comprises anair-powered cylinder.
 14. The method of claim 8, wherein operation ofthe leading roller and operation of the trailing roller is based atleast in part on programming controlling operation of the actuator. 15.A tape head, comprising: a leading roller, to move on a first supportarm about a first pivot, wherein the leading roller is configured topress tape against a leading side and a top side of a case; a trailingroller, to move on a second support arm about a second pivot, whereinthe trailing roller is configured to press the tape against the top sideand a trailing side of the case; and a linkage to connect the first andsecond support arms of the leading roller and the trailing roller,respectively, and to move the leading roller and the trailing roller inresponse to action by a roller-controlling actuator; wherein theroller-controlling actuator is configured to press the leading andtrailing rollers against the tape to seal flaps of the case.
 16. Thetape head of claim 15, wherein operation of the leading roller andoperation of the trailing roller is based at least in part onprogramming controlling operation of the roller-controlling actuator.17. The tape head of claim 15, wherein the roller-controlling actuatoris an air-powered cylinder powered by compressed air and configured toallow the compressed air to be introduced, in an alternating manner, toeach end of the air-powered cylinder.
 18. The tape head of claim 15,wherein the roller-controlling actuator is operated in response tooperation of a processing unit, memory and programming defined in thememory.
 19. The tape head of claim 15, additionally comprising: a tapeguide configured to position tape for contact with a second case. 20.The tape head of claim 15, additionally comprising: a knife to cut thetape; and a knife-controlling actuator to move the knife.